Vented LED display and method of manufacturing

ABSTRACT

A vented LED display is described including an LED display panel having a plurality of LEDs disposed thereon and defining a plurality of vent slots between the plurality of LEDs, each of the plurality of vent slots having a vent height. The vented LED display also includes a unitary injection-molded vent having a plurality of louvers and coupled to the LED display panel such that each louver corresponds to at least one vent slot and includes a louver length extending downwardly to at least 75% of the vent height of the corresponding vent slot.

FIELD OF THE INVENTION

The present invention relates generally to LED displays, and, moreparticularly, relates to a vented LED display and method ofmanufacturing the same.

BACKGROUND OF THE INVENTION

Outdoor light-emitting diode (LED) signs are known for various purposes,such as for traffic signage, advertisement billboards, outdoor sportingevents, etc. Outdoor LED signs have many challenges, such asruggedization to withstand outdoor environmental conditions (e.g., wind,rain, dust/debris, and other weather and temperature conditions), powerrequirements and heat dissipation for the multitude of LEDs required todisplay outdoor viewable messages and content, accessibility to internalcomponents for maintenance purposes, brilliance and contrast in the LEDpixels, and costs associated with manufacturing such often largestructures, to name a few.

Often, improvements in one area will result in drawbacks associated withanother area. For example, one problem with outdoor LED signs isincreasing the brilliance and contrast of the LED pixels, while not alsoincreasing power consumption of the LED sign and heat generation.Further, increased power consumption and heat generation will oftenresult in the need to construct heavier, more complicated systems, whichin-turn increases manufacturing costs. U.S. Pat. No. 6,169,632(Kurtenbach et al.) attempted to at least solve some of these problemsby creating a modular display system in which each modular display panelincluded a circuit board with various LED pixels mounted in a housing.Further, the modular display panels in Kurtenbach et al. includes louverpanels interspersed with the LED pixels to shade the LED pixels fromambient light, thereby improving the view contrast and viewability. Inaddition, each modular display panel in Kurtenbach et al. is secured toone or more modular support members by quick connect latches andincludes a driver board and a power supply securable to the modulardisplay by twist-on fasteners. Accessibility is provided on both sidesof the Kurtenbach et al. display system through the quick connectlatches and ready removability of the circuit boards and louver panels.

Unfortunately, the modular display system in Kurtenback et al. sufferedfrom at least one major drawback. For outdoor LED signs, there is aproblem of high wind resistance due to their solid surfaces and theirconsiderable size, which is often required in order for the LED pixelsto be visible from long distances. Further, outdoor LED signs are oftenplaced at higher altitudes for greater visibility, which increases thewind resistance even more because wind resistance tends to increase athigher altitudes.

U.S. Pat. No. 7,407,306 (DeMarb et al.) addressed this problem byproviding an aerodynamic display panel with a plurality of stackedlayers wings with space between the layers to allow air, rain, and otherelements to pass through. Unfortunately, the DeMarb et al. aerodynamicdisplay panel suffers from a multitude of drawbacks. Initially, thelayers have a wing-shaped cross-section which, as wind flows through thewing layers, results in a lifting force caused by the pressuredifference above the wing as compared to the pressure below the wing.Accordingly, such lifting forces will create a strain on the aerodynamicdisplay panel. In addition, the risk of wind forces knocking down thedisplay panel of DeMarb et al. is increased as a result of bothhorizontal wind forces and vertical lifting forces acting on the displaypanel simultaneously. In addition, each layer in DeMarb et al. is aseparate enclosure for an LED to provide protection to the electricalcomponents from environmental hazards. Unfortunately, such designresults in a rather complicated and difficult to assemble andmanufacture display panel including horizontal support receivers andvertical support receivers built into each layer and correspondingvertical and horizontal support beams to be routed through suchreceivers in order to assemble the display and support the layerenclosures thereon. Accordingly, the manufacturing and assembling theDeMarb et al. aerodynamic display panel would be rather costly andtime-consuming. Furthermore, the DeMarb et al. aerodynamic display panelis not readily accessible for maintenance purposes. If even one of thelayers requirement repair or replacement, it would be rather timeconsuming to disassemble the display panel in order to perform therepair or replacement. Also, it would be difficult to selectivelyprogram the DeMarb et al. sign to display varying messages and/orcontent on-the-fly as each layer is a separate enclosure shielding itselectrical components from environmental hazards.

Therefore, a need exists to overcome the problems with the prior art asdiscussed above.

SUMMARY OF THE INVENTION

The invention provides a vented LED display and method of manufacturingthat overcomes the hereinafore-mentioned disadvantages of theheretofore-known devices and methods of this general type.

With the foregoing and other objects in view, there is provided, inaccordance with the invention, a vented LED display including an LEDdisplay panel having a plurality of LEDs disposed thereon and defining aplurality of vent slots between the plurality of LEDs, each of theplurality of vent slots having a vent height; and a unitaryinjection-molded vent having a plurality of louvers and coupled to theLED display panel such that each louver corresponds to at least one ventslot and includes a louver length extending downwardly to at least 75%of the vent height of the corresponding at least one vent slot.

In accordance with yet another feature of the present invention, eachlouver of the unitary injection-molded vent and each corresponding atleast one vent slot of the LED display panel together defining a fluidpathway shaped and configured to allow fluid to flow through the ventedLED display from a front face thereof through a rear face thereof.

In accordance with another feature of the present invention, the LEDdisplay panel is a borderless panel.

In accordance with an additional feature of the present invention, theLED display panel is a unitary injection-molded structure.

In accordance with a further feature of the present invention, the LEDdisplay panel and the unitary injection-molded vent together form ahousing for one or more electronic components associated with theplurality of LEDs disposed on the LED display panel.

In accordance with another feature of the present invention, theplurality of LEDs disposed on the LED display panel is arranged as aplurality of horizontal LED rows disposed between the plurality of ventslots.

In accordance with yet another feature of the present invention, each ofthe plurality of louvers is disposed rearward of the at least onecorresponding vent slot.

In accordance with yet another feature, for each vent slot, thecorresponding louver includes an opaque surface disposed rearward of thevent slot and positioned to block light from passing through asubstantial portion thereof.

In accordance with a further feature of the present invention, the LEDdisplay panel is a unitary injection-molded structure including aplurality of LED shades positioned above each of the plurality of LEDsdisposed on the LED display panel so as to block light emitting from theplurality of LEDs in a vertical direction.

In accordance with another feature of the present invention, each of theplurality of louvers includes a cross-section with a first convexportion disposed forward of and transitioning into a second convexportion when viewed from a rear face of the unitary injection-moldedvent.

In accordance with yet another feature of the present invention, thefirst convex portion forms at least a portion of an electrical componenthousing for the plurality of LEDs disposed on the LED display panel; andthe second convex portion forms the louver length extending downwardlyto at least 75% of the vent height of the corresponding at least onevent slot.

In accordance with another feature of the present invention, theplurality of LEDs disposed on the LED display panel is arranged as aplurality of LED rows disposed between the plurality of vent slots; andeach of the plurality of LED rows extends from edge-to-edge on the LEDdisplay panel such that when an adjacent vented LED display is coupledthereto to form an outdoor LED sign each of the LED rows forms acontinuous LED row with one or more horizontally adjacent vented LEDdisplays coupled thereto.

In accordance with another feature, an embodiment of the presentinvention also includes a vented LED display having a monolithic LEDdisplay panel having LEDs disposed thereon in a matrix arrangement ofrows and columns separated by one or more vent slots between the rows;and a vent formed as a unitary structure, coupled to the monolithic LEDdisplay panel, and having a plurality of louvers, each of the pluralityof louvers corresponding to at least one of the one or more vent slotsso as to define a fluid pathway shaped and configured to allow fluid toflow through the vented LED display from a front face thereof through arear face thereof.

In accordance with another feature of the present invention, each of themonolithic LED display panel and the vent are at least one of aninjection molded structure and a die-cast structure.

In accordance with another feature of the present invention, each of theplurality of louvers is disposed rearward of the monolithic LED displaypanel.

In accordance with yet another feature, an embodiment of the presentinvention includes a method of manufacturing a vented LED display, themethod including steps of providing a first three-dimensional patternformed on a molding surface of a first mold; and injecting a polymericfluid material into the first mold and curing the polymeric fluidmaterial in the first mold so as to form a first injection-molded memberincluding an LED display panel surface defining one or more vent slots,each vent slot including a vent height. Further, the method may alsoinclude providing a second three-dimensional pattern formed on a moldingsurface of a second mold; and injecting a polymeric fluid material intothe second mold and curing the polymeric fluid material in the secondmold so as to form a second injection-molded member including aplurality of louver surfaces arranged so that each louver surfaceincludes a louver length that extends downwardly to at least 75% of thevent height.

In accordance with a further feature of the present invention, themethod includes coupling LEDs to a printed circuit board (PCB) so thatthe LEDs are in a matrix arrangement of rows and columns.

In accordance with another feature of the present invention, the methodincludes after the step of coupling LEDs to the PCB, positing the PCBbetween the first and second injection-molded members and coupling thefirst injection-molded member to the second injection-molded member toform the vented LED display with the one or more vent slots between therows of LEDs.

Although the invention is illustrated and described herein as embodiedin a vented LED display and method of manufacturing, it is,nevertheless, not intended to be limited to the details shown becausevarious modifications and structural changes may be made therein withoutdeparting from the spirit of the invention and within the scope andrange of equivalents of the claims. Additionally, well-known elements ofexemplary embodiments of the invention will not be described in detailor will be omitted so as not to obscure the relevant details of theinvention.

Other features that are considered as characteristic for the inventionare set forth in the appended claims. As required, detailed embodimentsof the present invention are disclosed herein; however, it is to beunderstood that the disclosed embodiments are merely exemplary of theinvention, which can be embodied in various forms. Therefore, specificstructural and functional details disclosed herein are not to beinterpreted as limiting, but merely as a basis for the claims and as arepresentative basis for teaching one of ordinary skill in the art tovariously employ the present invention in virtually any appropriatelydetailed structure. Further, the terms and phrases used herein are notintended to be limiting; but rather, to provide an understandabledescription of the invention. While the specification concludes withclaims defining the features of the invention that are regarded asnovel, it is believed that the invention will be better understood froma consideration of the following description in conjunction with thedrawing figures, in which like reference numerals are carried forward.The figures of the drawings are not drawn to scale.

Before the present invention is disclosed and described, it is to beunderstood that the terminology used herein is for the purpose ofdescribing particular embodiments only and is not intended to belimiting. The terms “a” or “an,” as used herein, are defined as one ormore than one. The term “plurality,” as used herein, is defined as twoor more than two. The term “another,” as used herein, is defined as atleast a second or more. The terms “including” and/or “having,” as usedherein, are defined as comprising (i.e., open language). The term“coupled,” as used herein, is defined as connected, although notnecessarily directly, and not necessarily mechanically. The term“providing” is defined herein in its broadest sense, e.g.,bringing/coming into physical existence, making available, and/orsupplying to someone or something, in whole or in multiple parts at onceor over a period of time.

As used herein, the terms “about” or “approximately” apply to allnumeric values, whether or not explicitly indicated. These termsgenerally refer to a range of numbers that one of skill in the art wouldconsider equivalent to the recited values (i.e., having the samefunction or result). In many instances these terms may include numbersthat are rounded to the nearest significant figure. In this document,the term “longitudinal” should be understood to mean in a directioncorresponding to an elongated direction of the LED display panel. Theterms “program,” “software application,” and the like as used herein,are defined as a sequence of instructions designed for execution on acomputer system. A “program,” “computer program,” or “softwareapplication” may include a subroutine, a function, a procedure, anobject method, an object implementation, an executable application, anapplet, a servlet, a source code, an object code, a sharedlibrary/dynamic load library and/or other sequence of instructionsdesigned for execution on a computer system.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying figures, where like reference numerals refer toidentical or functionally similar elements throughout the separate viewsand which together with the detailed description below are incorporatedin and form part of the specification, serve to further illustratevarious embodiments and explain various principles and advantages all inaccordance with the present invention.

FIG. 1 is a front, perspective view of a vented LED display, showing anLED display panel with a matrix arrangement of LEDs disposed thereon anda plurality of vent slots between rows of LEDs, in accordance with anembodiment of the present invention;

FIG. 2 is a partial, enlarged view of a single vent slot of the ventedLED display of FIG. 1, in accordance with an embodiment of the presentinvention;

FIG. 3 is a rear, perspective view of the vented LED display of FIG. 1,showing a vent with a plurality of louvers disposed rearward of the LEDdisplay panel, in accordance with an embodiment of the presentinvention;

FIG. 4 is a rear, side perspective view of the vented LED display ofFIG. 1, in accordance with an embodiment of the present invention;

FIG. 5 is a cross-sectional side view of a single louver of the ventedLED display of FIG. 1, in accordance with an embodiment of the presentinvention;

FIG. 6 is a front, upward-looking, perspective view of the vented LEDdisplay of FIG. 1, showing the louvers providing opaque surfacesrearward of the vent slots for providing an appearance of solidconstruction to upward-looking viewers, in accordance with an embodimentof the present invention;

FIG. 7 is a side view of the vented LED display of FIG. 1, in accordancewith an embodiment of the present invention;

FIG. 8 is partial, enlarged side view of the vented LED display of FIG.1, in accordance with an exemplary embodiment of the present invention;

FIG. 9 is a front, perspective view of an assembled outdoor LED signwith a plurality of vented LED displays coupled together to form theoutdoor LED sign, in accordance with an embodiment of the presentinvention;

FIG. 10 is a partial, rear, perspective view of the assembled outdoorLED sign of FIG. 9, in accordance with an embodiment of the presentinvention;

FIG. 11 is an elevational rear view of the outdoor LED sign of FIG. 9,in accordance with an embodiment of the present invention;

FIG. 12 is an elevational left side view of the outdoor LED sign of FIG.9, in accordance with an embodiment of the present invention;

FIG. 13 is a bottom view of the outdoor LED sign of FIG. 9, inaccordance with an embodiment of the present invention;

FIG. 14 an elevational front view of the outdoor LED sign of FIG. 9, inaccordance with an embodiment of the present invention;

FIG. 15 is a top plan view of the outdoor LED sign of FIG. 9, inaccordance with an embodiment of the present invention;

FIG. 16 is an elevational right side view of the outdoor LED sign ofFIG. 9, in accordance with an embodiment of the present invention; and

FIG. 17 is a flow chart of an exemplary method of manufacturing a ventedLED display, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

While the specification concludes with claims defining the features ofthe invention that are regarded as novel, it is believed that theinvention will be better understood from a consideration of thefollowing description in conjunction with the drawing figures, in whichlike reference numerals are carried forward. It is to be understood thatthe disclosed embodiments are merely exemplary of the invention, whichcan be embodied in various forms.

The present invention provides a novel and efficient vented LED displaymodule that is particularly suitable for outdoor usage as an outdoor LEDsign. Embodiments of the invention provide a vented LED display modulewith a front face having a plurality of LEDs disposed thereon in amatrix arrangement of LED rows and columns, the front face defining aplurality of vent slots disposed between LED rows to reduce the windresistance of the LED sign. In addition, embodiments of the inventionprovide a rear face formed as a unitary vent having a plurality oflouvers that, when the unitary vent is coupled to the front face,defines a plurality of fluid pathways that allows air to flow completelythrough the vented LED display module. In a further embodiment, thevented LED display module is operably configured to allow air to flowthrough the vent slots and be directed downward by the correspondinglouver. Stated another way, embodiments of the present invention allowair to flow through a matrix arrangement of vent slots defined by thefront face and out through the rear face through the plurality oflouvers. In addition, embodiments of the present invention provide forthe louvers to extend downwardly past a substantial height of thecorresponding vent slot so as to provide a contrasting opaque surfacefor the sign, enhancing viewability thereof by viewers viewing from thesign from the front face.

Referring now to FIG. 1, one embodiment of the present invention isshown in a front, perspective view. FIG. 1 shows several advantageousfeatures of the present invention, but, as will be described below, theinvention can be provided in several shapes, sizes, combinations offeatures and components, and varying numbers and functions of thecomponents. The first example of a vented LED display 100, as shown inFIG. 1, includes an LED display panel 102 having a plurality of LEDs 104disposed thereon.

The LED display panel 102 can be considered a structure on which theLEDs 104 are disposed and that forms a front, viewing side of the ventedLED display 100. Such front, viewing side of the LED display panel 102can be considered a front face 106 of the vented LED display panel 102.As used herein, the term “front face” is intended to indicate one ormore surface(s) on the front side of the LED display panel 102 that areviewable by a user viewing the vented LED display 100 from the frontside, where the LEDs 104 are disposed. In a preferred embodiment, thefront face 106 is an opaque surface of a dark color (e.g., black) so asto provide a contrasting surface for the lights emitting from the LEDs104. In another embodiment, the front face 106 is the same color as thelouvers so as to provide a uniform appearance (discussed herein in moredetail below). As used herein, unless otherwise expressly indicatedherein, any discussion of orientation, direction, disposition, position,or other configuration of elements of the vented LED display 100 and anycomponents thereof pertains to the display 100 in its operationalconfiguration, in an upright orientation, perpendicular to a planarground surface. Further, terms such as, “front,” “back,” “rear,”“forward,” “rearward,” “top,” “bottom,” “up,” “down,” “downwardly,”“left and right sides,” and the like, are indicated from the referencepoint of a viewer viewing the LED display 100 from its front face 106,where the LEDs 104 are disposed.

In a preferred embodiment, the LED display panel 102 is a unitarystructure. Advantageously, this provides a significant advantage overprior art LED displays that are more complicated to manufacture,assemble, repair, and access for maintenance purposes, as discussedabove. In one preferred embodiment, the LED display panel 102 is aunitary injection-molded structure. As used herein, the term “molded”may be used without the term “injection,” yet it is understood that theterm “molded” refers to a structure that has been formed from aninjection-molding manufacturing process, as is known in the art. In analternative embodiment, the LED display panel 102 may be formed as aunitary metallic structure through a die casting manufacturing process,rather than as a unitary polymer-based structure, as with theinjection-molding process. In other embodiments, the LED display panel102 may be formed with other types of manufacturing processes.

In one embodiment, the front face 106 is formed with a generally planarsurface. In a further embodiment, the front face 106 may includeminiscule ridges and/or grooves not readily visible by viewers from afar distance. In other embodiments, the front face 106 may be providedas other shapes and configurations, such as a slightly curved surface,for example. In yet other embodiments, the front face 106 may include aplurality of shades 108 (see also FIG. 8 for an enlarged view of theshades 108). The shades 108 may be disposed directly above the LEDs 104for various purposes, such as, for example, to block light emitting in avertical direction from rows of LEDs above and below for greater visualclarity, to shield the LEDs 104 from environmental elements, and thelike. In a preferred embodiment, the shades 108 are integral to thefront face 106 of the LED display panel 102 for ease of assembly. Forexample, the LED display panel 102 may be a unitary injection-moldedstructure with the plurality of shades 108. In another embodiment, theLED display panel 102 may be a unitary die cast structure with theplurality of shades 108. In an alternative embodiment, the shades 108may be coupled to the LED display panel 102 during the manufacturingprocess, after the body providing the primary structure for the LEDdisplay panel 102 is formed. In yet other embodiments, the front face106 may be provided with other components and features.

Importantly, the LED display panel 102 is a vented display panel,defining a plurality of vent slots 110 between the LEDs 104. As usedherein, the term “vent slot” is intended to indicate a through-openingthat allows fluid, such as air and liquid, to pass through from one sideand out through the other opposing side. Although the term “slot” isused in the term “vent slot,” the invention is not intended to belimited to a particular shaped opening, and is intended in its mostbroad sense to be inclusive of any shape of through-opening that thatallows fluid to pass through from one side and out through the otheropposing side of the LED display panel 102. The vent slots 110 may be,for example, rectilinear shaped, as shown in the exemplary embodiment.In another embodiment, the vent slots 110 may be circular, oroval-shaped. In yet another embodiment, the vent slots 110 may beelongated and narrow, or, alternatively, may be short and wide. In yetanother embodiment, the plurality of vent slots 110 may each be the sameshape. In an alternative embodiment, the plurality of vent slots 110 maybe provided in shapes that vary from one to another.

In one embodiment, one or more vent slots 110 are defined by the LEDdisplay panel 102 between LED rows 114. In a further embodiment, one ormore vent slots 110 are defined by the LED display panel 102 betweenhorizontal rows of LEDs 114. Stated another way, the LEDs 104 may bedisposed on the LED display panel 102 arranged as a plurality ofhorizontal rows of LEDs 114 disposed between one or more vent slots 110.There may be provided a single vent slot 110 between LED rows 114, ormore than one vent slots 110 between LED rows 114 as in the exemplaryembodiment. In such embodiment, the one or more vent slots 110 may behorizontally aligned to form a row of vent slots 110 between LED rows114. In one embodiment, there may be more than one LED row 114 disposedbetween rows of vent slots 110. For example, in order to increase thenumber of LED pixels provided on the LED display panel 102, there can beprovided a pair of horizontal LED rows 114 disposed between each row ofvent slots 110, as in the exemplary embodiment. In other embodiments,there may be provided less than or more than two rows of LEDs 114between rows of vent slots 110.

In one embodiment, the LED display panel 102 can be considered amonolithic LED display panel 102 with LEDs disposed thereon in a matrixarrangement of rows 114 and columns 116 of LEDs 104 separated by one ormore vent slots 110 between the rows 114. In another embodiment, theplurality of LEDs 104 may be disposed on the LED display panel 102 inother patterns and configurations. For example, in one embodiment, theplurality of LEDs 104 may be arranged in diagonal lines. In anotherembodiment, the plurality of LEDs 104 may be arranged as acircular-shaped matrix, rather than a rectangular matrix arrangement, asdepicted in the exemplary embodiment. There are many arrangements ofLEDs 104 that can be provided in various embodiments of the presentinvention and a multitude of interspersed vent slot 110 arrangements toprovide for venting of outdoor wind and elements through the LED display100, in accordance with the present invention.

Moreover, the LEDs 104 can be any type of lighting element, such as, forexample, miniature LEDs, RGB LEDs, white LEDs, blue LEDs, red LEDs,green LEDs, OLEDs, and the like. In yet other embodiments, the lightingelement may be a DIP (dual in-line package) or an SMT (surface mounttechnology) LED. The DIP is commonly known in the art to be operable toemit a single color (either red, green, or blue). On the other hand, SMTprovides a wider range of variable color combinations, as SMT LEDsinclude red, green, and blue LEDs in a single SMT LED. As is known inthe art, SMT may also be referred to as SMD (surface mounted device)LED. In one embodiment, the LEDs 104 are disposed external to the ventedLED display 100 (see FIG. 8 for a close-up view of the LED 104). Inanother embodiment, the LED display panel 102 defines a plurality ofapertures with at least a portion of each LED 104 disposed in one of theplurality of apertures. Preferably, the aperture and the correspondingLED 104 disposed therein form a water-tight seal so as to preventenvironmental elements from reaching any of the other electricalcomponents that may be housed within the vented LED display 100.

Referring now to FIG. 2, an enlarged, partial front view of the LEDdisplay 100 is depicted illustrating one embodiment of the vent slot110. Each of the vent slots 110 may include a vent height 200. In afurther embodiment, each of the vent slots 110 may also include a topedge 202 and a bottom edge 204 and the vent height 200 may extend fromthe top edge 202 to the bottom edge 204. In other words, in oneembodiment, the vent height 200 is defined as a vertical distancebetween the top edge 202 to the bottom edge 204. As used herein, theterm “edge” is intended to indicate an outside limit of an object, area,or surface.

Referring now to FIGS. 3-4, the vented LED display 100 may also includea vent 300 couplable to the LED display panel 102 (not shown). The vent300, advantageously, allows fluid to flow through to the other side fromthe vent slots 110, in order to reduce wind resistance for the outdoorLED sign, while simultaneously providing an opaque surface spanning atleast a portion of the openings of the vent slots 110 so as to provide acontrasting surface for the lights.

In a preferred embodiment, the vent 300 is a unitary structure.Advantageously, this provides a significant advantage over prior art LEDdisplays that are more complicated to manufacture, assemble, repair, andaccess for maintenance purposes, as discussed above. In one preferredembodiment, the vent 300 is a unitary injection-molded structure. In analternative embodiment, the vent 300 may be formed as a unitary metallicstructure through a die casting manufacturing process. In otherembodiments, the vent 300 may be formed with other types ofmanufacturing processes.

The vent 300 may include a plurality of louvers 302. In a preferredembodiment, the plurality of louvers 302 are formed on the vent 300through an injection-molding process so that the vent 300 can be easilycoupled to the vented LED display panel 102 to form the vented LEDdisplay 100. As used herein, the term “louver” is intended to indicateeach of a set of angled slats and/or flaps arranged so that at least aportion of the louver allows fluid to pass through. In one embodiment,the plurality of louvers 302 are arranged at regular intervals on thevent 300. Stated another way, each of the plurality of louvers 302 arevertically equidistant from one another. In an alternative embodiment,the plurality of louvers 302 may be arranged at non-regular intervals onthe vent 300.

Referring briefly to FIG. 5, an exemplary embodiment of the louver 302is illustrated in a cross-sectional, side view of one of the pluralityof louvers 302. The louver 302 may be provided in many shapes andconfiguration in various embodiments. For example, the louver 302 may beshaped with a curved surface, or may be provided with a substantiallyplanar (90%+/−10 of the surface of the louver is planar) angled surface.Preferably, the louver 302 is shaped so as to maximize the reduction ofwind resistance. In a preferred embodiment, the louver 302 includes across-section with a first convex portion 500 and a second convexportion 502 when viewed from a rear face 400 (FIG. 4) of the vent 300.As used herein, the term “rear face” is intended to indicate surface(s)on the rear side of the vent 300 that are viewable by a user viewing therear side of the vented LED display 100, opposite the front side wherethe LEDs 104 are disposed. In one embodiment, the first convex portion500 can be considered disposed forward of the second convex portion 502.In other words, the first convex portion 500 may be disposed closer tothe front face 106 than the second convex portion 502. In a furtherembodiment, the first convex portion 500 may be continuous with thesecond convex portion 502. Stated another way, the first convex portion500 may transition into the second convex portion 502. In oneembodiment, the louver 302 may be considered to include two adjacentcurves or arcs. In another embodiment, the first convex portion 500 mayform at least a portion of an electrical component housing forelectrical components of the LEDs 104 (see FIG. 1) disposed on the LEDdisplay panel 102 (see FIG. 1). In yet another embodiment, the secondconvex portion 502 provides the opaque surface that spans at least aportion of the openings of the vent slots 110 (see FIG. 2) so as toprovide a contrasting surface for the lights.

Referring again to FIG. 2, with brief reference to FIGS. 1 and 4, whenthe vent 300 and the LED display panel 102 are coupled together to formthe LED display 100, each of the plurality of louvers 302 may correspondto at least one vent slot 110. In other words, each of the plurality oflouvers 302 is arranged or positioned to align with at least one ventslot 110 when the vent 300 and panel 102 are coupled together in anoperational configuration. More specifically, in some embodiments, eachof the plurality of louvers 302 is disposed rearward of thecorresponding vent slot 110. Such arrangement forms a fluid pathway 206shaped and configured to allow fluid to flow through the vented LEDdisplay 100 from the front face 106 through the rear face 400 forreducing wind resistance. As used herein and for the sake of brevity,the fluid pathway 206 is described herein as allowing fluid to flow fromthe front face through the rear face; however, it is understood that theshape and configuration of the fluid pathway 206 also allows fluid toflow through the vented LED display 100 in the other direction, from therear face 400 through the front face 106. As is known in the art, thedirection of fluid flow (e.g., wind) will depend on the direction thatsuch environmental elements are traveling as they encounter the ventedLED 100 in an outdoor environment. In addition, the fluid pathway 206may allow rain and other elements through and may also assist withdissipating heat generated by the LEDs 104. In a further embodiment,each of the plurality of louvers 302 is considered to extend rearwardlyand downwardly from the top edge 202 of the corresponding vent slot 110.In another embodiment, each of the plurality of louvers 302 is disposedrearward of the LED display panel 102.

In addition, in one embodiment, the louver 302 includes a louver length208 that extends downwardly to at least 75% of the vent height 200 ofthe corresponding vent slot 110. Advantageously, this may provide asurface which, when the vented LED display 100 is viewed from certainangles, provides for a display that appears to viewers to be of solidconstruction, without any through-openings or vents. Referring brieflynow to FIG. 6, in one embodiment, the louvers 302 are shaped andoriented such that when viewed by a viewer from an upward-looking angle,as in FIG. 6, the louvers 302 provide a sufficient louver length 208that the vented LED display 100 appears to be of a solid construction.As is known in the art, outdoor signs are often positioned relativelyhigh to maximize visibility in an outdoor environment and, therefore,are often viewed by viewers from an upward-looking angle. Accordingly,embodiments of the vented LED display 100 provide the advantage of aventing construction with the appearance of a solid panel body whenviewed from certain angles. In one embodiment, the LED display 102 andthe louvers 302 are of the same color (e.g., black) and/or the samematerial (e.g., polymer-based) so as to further provide a solid uniformappearance to viewers. In addition, preferred embodiments of the ventedLED display 100 are provided with injection-molded members that areeasily coupled together for ease of manufacturing, reducing costs andcomplexity associated therewith.

Referring again to FIG. 2, with brief reference to FIGS. 1 and 4, in oneembodiment, the louver 302 is of an opaque material so as to provide anopaque surface, blocking light from passing through a substantialportion of the vent slot 110. Stated another way, the louver 302 mayinclude an opaque surface disposed rearward of the vent slot 110 andpositioned to block light from passing through a substantial portion ofthe vent slot 110. As used herein, the term “substantial portion” isintended to indicate at least 75% of the vent slot 110. In otherembodiments, the louver 302 may also include surfaces that aretransparent or semi-transparent. More specifically, in some embodiments,the second convex portion 502 (FIG. 5) provides the louver length 208that extends downwardly to at least 75% of the vent height 200 of thecorresponding vent slot 110. In other embodiments, the louver length 208extends downwardly to at least 80% of the vent height 200. In yet otherembodiments, the louver length 208 extends downwardly to at least 90% ofthe vent height 200. In yet further embodiments, the louver length 208extends downwardly to more than 90% of the vent height 200.Advantageously, the louver 302 may provide an opaque surface such thatvented LED display 100 appears to be of solid construction, while thevent slots 110 allow the vented LED display 100 to be vented and toreduce wind resistance for the outdoor sign.

Referring now to FIGS. 7-8, the vented LED display 100 is illustrated ina side view and an enlarged partial side view, respectively, showing theLED display panel 102 and the vent 300 coupled together in anoperational configuration. In one embodiment, each of the LED displaypanel 102 and the vent 300 may be a unitary structure, such as aninjection-molded member, that can be relatively easily coupled together.The LED display panel 102 and the vent 300 may be coupled together in amultitude of ways, such as, for example, with various types of fasteners(e.g., screws, bolts, snaps, friction-fit fasteners, adhesives,hook-and-loop fasteners, dowel fasteners, and the like). In oneembodiment, the LED display panel 102 and the vent 300 together form ahousing for one or more electronic components associated with the LEDs104 disposed on the LED display panel 102. In another embodiment, onlyone of the LED display panel 102 and the vent 300 is a unitarystructure. In yet another embodiment, the vented LED display 100 may beformed as a single unitary structure, rather than, for example, twoseparate injection-molded members. In yet other embodiments, the LEDdisplay panel 102 and the vent 300 may be shaped, formed, and/orconfigured in other ways. In one embodiment, the electronic componentsinclude a printed circuit board (PCB) 700. The PCB 700 may mechanicallysupport and electrically connect the LEDs 104 by, for example, a patternof conductive tracks etched onto a non-conductive substrate. The LEDdisplay panel 102 may be considered a “mask.” The mask may be formed asa relatively thin panel defining the plurality of apertures for the LEDs104 and a plurality of vent slots 110 between rows of apertures. Suchmask functions as the front face 106 for the vented LED display 100 toconceal and protect the PCB 700 and form at least a portion of thehousing.

Referring to FIGS. 5 and 9, in one embodiment, the LED display panel 102may be formed as a borderless panel. Advantageously, this improves theseamless appearance of a modular embodiment of the vented LED display100. In other words, and with specific reference to FIG. 9, an outdoorLED sign 900 may be formed by coupling a plurality of vented LEDdisplays 100 a-n together to form a continuous pattern of LED pixelsspanning across the surface area of the outdoor LED sign 900. As usedherein, the number of vented LED displays between “a” through “n” can beany number. This is an improvement over prior art LED panels thatinclude borders outlining a periphery of the LED panel such that if suchLED panels were coupled together to form a larger sign, the borderswould interfere with the uniform appearance of the sign. Stated anotherway, in one embodiment, the LED rows 114 disposed on each of theplurality of vented LED displays 100 a-n extends from edge-to-edge suchthat when the LED display panel 100 is coupled to adjacent LED displaypanels 100 to form the outdoor LED sign 900 each of the LED rows 114forms a continuous LED row 114 with adjacent vented LED displays 100coupled thereto.

Referring now to FIG. 10, the outdoor LED sign 900 may include a supportframe 1000 on which the vented LED displays 100 are mounted. The outdoorLED sign 900 may also include a housing 1002 for a main board 1004communicatively coupled to and operably configured to power and/orcontrol the LEDs 104 (not shown). In one embodiment, the main board 1004is a programmable board that allows users to selectively program amessage to be displayed on the outdoor LED sign 900. In anotherembodiment, the housing 1002 may include a hinged or pivotable door 1006that can be easily opened and closed to access the main board 1004 forselective programming and/or repair and replacement of the same. Themain board 1004 can be provided as a printed circuit board for dataprocessing that includes at least a portion that is programmable. Inother embodiments, the main board 1004 may be considered a “motherboard”that includes one or more CPUs (central processing units). In oneembodiment, the main board 1004 may be provided with a port that allowsservice technicians to plug-in an electronic device that interfaces withthe main board 1004 and allows the service technician to selectivelyprogram messages. In other embodiments, the main board 1004 does notallow for selective programmability of messages to be displayed on theoutdoor LED sign 900. In such embodiments, the main board 1004 may beprogrammed or manufactured with a pre-set message at the manufacturingsite for the board.

Referring now to FIGS. 11-16, various views an exemplary embodiment ofthe outdoor LED sign 900 are illustrated. FIG. 11 is an elevational rearview of the outdoor LED sign 900 showing the vent 300 and louvers 302.In the exemplary embodiment, the outdoor LED sign 900 includes 8 (eight)vented LED displays 100 coupled together (more specifically, 4 (four)vented LED displays 100 coupled together, one above the other, on eachopposing side of the housing 1002). In other embodiments, there may beprovided other numbers and configurations of vented LED displays 100coupled together to form the outdoor LED sign 900. In yet otherembodiments, the outdoor LED sign 900 may be yet another modular elementof yet a larger LED sign, such as an LED billboard. In such embodiments,a multitude of the outdoor LED signs 900, which may also be referred toas cabinets, are coupled together to form a larger outdoor sign. In anexemplary embodiment, an LED billboard may be made up of a 4×19 array ofmodular outdoor LED signs 900 coupled together to provide a single sign.

FIGS. 12 and 16 show elevational side views of opposing sides of theoutdoor LED sign 900. As can be seen, in the exemplary embodiment, thelouvers 302 (not shown) do not extend beyond the sidewalls so as toprovide a modular and compact design. FIGS. 13 and 15 shows a top planview and bottom view, respectively, of the outdoor LED sign 900. FIG. 14shows an elevational front view of the outdoor LED sign 900 showing theLED display panels 102 defining the plurality of vent slots 110 to allowfluid to pass therethrough. For the sake of clarity of the arrangementsof the vent slots 110, the LEDs 104 and the louvers 302 are not shown inFIG. 14. Although not readily apparent from FIG. 14, in a preferredembodiment, the louvers 302 are formed with an opaque surface thatextends downwardly covering a substantial portion of the vent height 200to provide the outdoor LED sign 900 with an appearance of solidconstruction, when viewed at certain standard viewing angles.

An exemplary embodiment of a manufacturing process will be describedwith reference to the process flow chart of FIG. 17 in conjunction withFIGS. 1-4 and FIG. 7. Although the process flow chart of FIG. 17 shows aspecific order of executing the process steps, the order of executingthe steps may be changed relative to the order shown in certainembodiments. Also, two or more blocks shown in succession may beexecuted concurrently or with partial concurrence in some embodiments.Certain steps may also be omitted in FIG. 17 for the sake of brevity.

It is understood that that any molds and/or three-dimensional patternsdiscussed with reference to the process flow chart of FIG. 17 are formanufacturing embodiments of the LED display panel 102 and vent 300described herein above and depicted in FIGS. 1-16. Accordingly, it wouldbe understood by persons of ordinary skill in the art that the molds areformed with three-dimensional patterns that would produce the surfacesof the panel 102 and vent 300, as described herein above. Therefore, forthe sake of brevity, descriptions of such molding surfaces are notrepeated in the following section. Rather, the following section focusesprimarily on the manufacturing process steps.

The process may begin, at step 1700, and may immediately proceed to step1702, where a manufacturer may provide a first three-dimensional (3-D)pattern formed on a molding surface of a first mold, for forming one ormore surfaces of the LED display panel 102. In step 1704, a firstinjection-molded member is formed that includes an LED display panelsurface, such as the front face 106. The LED display panel surfacedefines one or more vent slots 110 arranged and configured as describedherein above, with reference to FIGS. 1-16. Further, each vent slot 110may include the vent height 200. More specifically, the manufacturer mayinject a polymeric fluid material into the mold such that the polymericfluid fills in cavities defined by the first three-dimensional pattern.After the polymeric fluid fills in the first three-dimensional pattern,the manufacturer may cure the polymeric fluid so as to harden, forming arigid first injection-molded member. The manufacturer may use any knowntype of injection molding machine(s) and any polymeric fluid (e.g.,resins, elastomers, thermoplastics, etc.) known in the art.

In step 1706, the manufacturer may provide a second three-dimensionalpattern formed on a molding surface of a second mold, different from thefirst mold, for forming one or more surfaces of the vent 300 and louvers302. In step 1708, a second injection-molded member including aplurality of louver surfaces is formed by the manufacturer by injectingthe polymeric fluid material into the second mold such that thepolymeric fluid fills in cavities defined by the secondthree-dimensional pattern. After the polymeric fluid fills in thecavities of the second three-dimensional pattern, the manufacturer maycure the polymeric fluid so as to harden the fluid, forming a rigidsecond injection-molded member including the plurality of louversurfaces. As discussed herein above, in a preferred embodiment, each ofthe plurality of louver surface includes a louver length 208 thatextends downwardly to at least 75% of the vent height 200.

In one embodiment, the first three-dimensional pattern may be formed soas to provide a plurality of apertures on the LED display panel 102through which the LEDs 104 may be coupled to the LED display panel 102.Accordingly, in step 1710, the manufacturer may couple the LEDs 104 tothe PCB 700 so that the LEDs 104 are arranged in the matrix arrangementof rows and columns, described and depicted herein above, separated bythe one or more vent slots 110 between the rows, when fully assembled.More particularly, the LEDs 104 are physically and electrically coupledto the PCB 700 to provide the electronic circuitry to control and emitlight from the LEDs 104.

In step 1712, after coupling the LEDs 104 to the PCB 700, themanufacturer may couple the PCB 700 between the first and secondinjection-molded members so as to form the vented LED display 100 inaccordance with the present invention. In other words, the PCB issandwiched between the first-injection-molded member and thesecond-injection-molded member. In one embodiment, a periphery of theLED display panel 102 is aligned and coupled to a periphery of the vent300 so as to form a seamless structure for the vented LED display 100.The first and second injection-molded members may be coupled to oneanother by any known fastener, such as, for example, screws, nuts,bolts, adhesives, etc. Advantageously, embodiments of the method ofmanufacturing the vented LED display 100 provide a more time-efficient,cost-efficient manufacturing process for making vented LED displays 100.In alternative embodiments, the vented LED display 100 may be formed bya die-cast manufacturing process.

In another embodiment, the PCB 700 (with the LEDs 104 disposed thereon)may be coupled to the vent 300 by fasteners, for example. Subsequently,the PCB 700 may be coupled to the LED display panel 102 by engaging thePCB 700 with a rear side of the LED display panel 102 so that each ofthe LEDs 104 can be inserted within a plurality of apertures, theapertures defined by the LED display panel 102. This manufacturing stepresults in the LEDs 104 being positioned forward of the front side ofthe LED display panel 102 so as to be visible to viewers (as can beclearly discerned in at least FIGS. 7-8). The LED display panel 102 maythen be secured to the vent 300 by, for example, fasteners, so as toform the vented LED display 100. The process may end at step 1714.

A novel and efficient vented LED display has been disclosed that isparticularly suitable for outdoor usage as an outdoor LED sign.Embodiments of the invention provide a vented LED display module with afront face having a plurality of LEDs disposed thereon in a matrixarrangement of LEDs, the front face defining a plurality of vent slotsdisposed between LEDs to reduce the wind resistance of the LED sign. Inaddition, embodiments of the invention provide a rear face formed as aunitary vent having a plurality of louvers that, when the unitary ventis coupled to the front face, defines a plurality of fluid pathways thatallows air to flow completely through the vented LED display module. Ina further embodiment, the vented LED display module is operablyconfigured to allow air to flow through the vent slots and be directeddownward by the corresponding louver. Stated another way, embodiments ofthe present invention allow air to flow through a matrix arrangement ofvent slots defined by the front face and out through the rear facethrough the plurality of louvers. In addition, embodiments of thepresent invention provide for the louvers to extend downwardly past asubstantial height of the corresponding vent slot so as to provide acontrasting opaque surface for the sign, enhancing viewability thereofby viewers viewing from the sign from the front face.

What is claimed is:
 1. A vented LED display comprising: an LED displaypanel having a plurality of LEDs disposed thereon and defining aplurality of vent slots, the plurality of LEDs disposed as one or morerows of LED pixels between the plurality of vent slots and each of theplurality of vent slots having a vent height and a vent length andformed as a through-opening of the LED display panel; and a unitaryinjection-molded vent being formed as a one-piece continuousinjection-molded vent, having a plurality of louvers, and coupled to theLED display panel such that at least a portion of each louver:corresponds to at least one vent slot so as to be disposed rearward ofand aligned with the at least one vent slot substantially along the ventlength of the at least one vent slot; includes a louver length extendingdownwardly to at least 75% of the vent height of the corresponding atleast one vent slot; and includes a cross-section with a first portionand a second portion, the first portion forming at least a portion of anelectrical component housing for at least one of the plurality of LEDsdisposed on the LED display panel and the second portion forming thelouver length extending downwardly to at least 75% of the vent height ofthe corresponding at least one vent slot.
 2. The vented LED display inaccordance with claim 1, wherein: each louver of the unitaryinjection-molded vent and each corresponding at least one vent slot ofthe LED display panel together defining a fluid pathway shaped andconfigured to allow fluid to flow through the vented LED display from afront face thereof through a rear face thereof.
 3. The vented LEDdisplay in accordance with claim 1, wherein: the LED display panel is aborderless panel.
 4. The vented LED display in accordance with claim 1,wherein: the LED display panel is a unitary injection-molded structure.5. The vented LED display in accordance with claim 1, wherein: the LEDdisplay panel and the unitary injection-molded vent together form ahousing for one or more electronic components associated with theplurality of LEDs disposed on the LED display panel.
 6. The vented LEDdisplay in accordance with claim 1, wherein: for each vent slot, thecorresponding louver includes an opaque surface disposed rearward of thevent slot and positioned to block light from passing through asubstantial portion thereof.
 7. The vented LED display in accordancewith claim 1, wherein: the LED display panel is a unitaryinjection-molded structure including a plurality of LED shadespositioned above each of the plurality of LEDs disposed on the LEDdisplay panel so as to block light emitting from the plurality of LEDsin a vertical direction.
 8. The vented LED display in accordance withclaim 1, wherein: the first portion and the second portion are convexportions when viewed from a rear face of the unitary injection-moldedvent.
 9. The vented LED display in accordance with claim 1, wherein: theplurality of LEDs disposed on the LED display panel is arranged as aplurality of LED rows disposed between the plurality of vent slots; andeach of the plurality of LED rows extends from edge-to-edge on the LEDdisplay panel such that when an adjacent vented LED display is coupledthereto to form an outdoor LED sign each of the LED rows forms acontinuous LED row with one or more horizontally adjacent vented LEDdisplays coupled thereto.
 10. A vented LED display comprising: an LEDdisplay panel having LEDs disposed thereon and defining a plurality ofvent slots, the LEDs disposed as one or more rows of LED pixels betweenthe plurality of vent slots, each of the plurality of vent slots has avent height and a vent length and is formed as a through-opening of theLED display panel; and a vent formed as a unitary one-piece continuousstructure, coupled to the LED display panel, and having a plurality oflouvers, at least a portion of each of the plurality of louvers:corresponding to at least one of the plurality of vent slots so as todefine a fluid pathway shaped and configured to allow fluid to flowthrough the vented LED display from a front face thereof through a rearface thereof; is disposed rearward of and aligned with the at least oneof the plurality of vent slots substantially along the vent length ofthe at least one of the plurality of vent slots; and includes across-section with a first portion and a second portion, the firstportion forming at least a portion of an electrical component housingfor at least one of the LEDs disposed on the LED display panel and thesecond portion forming a louver length that at least partially definesthe fluid pathway.
 11. The vented LED display in accordance with claim10, wherein: each of the plurality of louvers extends downwardly to atleast 75% of the vent height of the corresponding one of the pluralityof vent slots.
 12. The vented LED display in accordance with claim 10,wherein: each of the LED display panel and the vent are at least one ofan injection molded structure and a die-cast structure.
 13. The ventedLED display panel in accordance with claim 10, wherein: wherein thefirst portion and the second portion are convex portions when viewedfrom a rear face of the vent.